Test terminal connector

ABSTRACT

A test terminal connector for use in selectively interconnecting electrical leads of a railway circuit is provided and includes a mounting block; a first and a second terminal supported in and extending from the mounting block; a test strap supported on and extending between the first and second terminal; at least one fastening element selectively connectable to the first and second terminals; and a dielectric spacer disposed between the test strap and an electrical lead of the railway circuit. The test strap is constructed of an electrically conductive material, and each fastening element is constructed of the same material as the test strap.

CROSS-REFERENCE TO RELATED APPLICATION

This application is a continuation of U.S. application Ser. No.11/900,327, filed Sep. 11, 2007, which application is incorporated byreference herein.

BACKGROUND

1. Technical Field

The present disclosure relates to connectors and, more particularly, totest terminal connectors for use in railway systems, railway bungalowsand the like.

2. Background of Related Art

Railroad signals relays, test terminal connectors or terminal blockshave been used for many years. Typically, terminal blocks are installedin bungalows or field cases alongside the tracks. As these enclosuresare neither heated nor air-conditioned, the terminal blocks housedtherein may be subject to the effects of ambient conditions, such asmoisture, which may result in corrosion of the signal relay or the like.

Terminal blocks typically include a terminal strap extending between andselectively secured to a pair of mounting or terminal bolts by way ofsuitable binding or clamp nuts. Typically, the test strap is made ofcopper that is coated in or is plated with nickel; and at least one ofthe terminal bolts, in direct physical contact with the test strap, ismade of brass and may or may not be coated with gold. Over time, as theterminal bolts are tightened and loosened, the abrasion or slidingcontact between the dissimilar materials of the terminal bolt againstthe surface of the test strap may result in the creation of a highresistance contact therebetween. In other words, the terminal bolt maywear through the nickel coating of the test strap, exposing the innercopper material thereof. As such, the terminal block may cause thecircuit to which it is connected to intermit (i.e., opening and closingof the circuit) or fail, thus creating an unwanted situation.

The situation is exacerbated due to the possible exposure of theterminal block to moisture which may corrode or oxidize the exposedcopper of the test strap.

Accordingly, a need exists for improved terminal blocks for us withrailway circuits and the like.

SUMMARY

The present disclosure relates to test terminal connectors for use inrailway systems, railway bungalows and the like.

According to an aspect of the present disclosure, a test terminalconnector for use in selectively interconnecting electrical leads of arailway circuit is provided. The test terminal connector includes amounting block; a first and a second terminal supported in and extendingfrom the mounting block; a test strap supported on and extending betweenthe first and second terminal; at least one fastening elementselectively connectable to the first and second terminals; and adielectric spacer disposed between the test strap and an electrical leadof the railway circuit. The test strap is constructed of an electricallyconductive material, and each fastening element is constructed of thesame material as the test strap.

The test strap and each fastening element may be at least coated with atleast one of nickel and a nickel alloy.

Each terminal may be a mounting bolt and each fastening element is a nutconfigured for selective threaded engagement with a respective mountingbolt.

The test strap may include a first end connectable to the firstterminal; a second end connectable to the second terminal; and agoose-neck portion interconnecting the first end and the second end.Each end of the test strap may define an aperture configured to receivea respective terminal therein.

The dielectric spacer may include an aperture formed therein forreceiving one of the terminals, and a flange extending therefrom andbeing configured for positioning within the aperture of one of the firstand second ends of the test strap. A height of the flange of thedielectric spacer may be at least one of equal to and less than athickness of the test strap.

In an embodiment, the at least one fastener supported on the terminalthat supports the dielectric spacer may contact the test strap when theat least one fastener is at a lowest most position on the terminal.

The dielectric spacer may include a pair of arms extending therefrom andconfigured to extend at least partially around the test strap. In use,the arms maintain the dielectric spacer supported on the test strap.

The test terminal connector may further include a spacer disposed belowone of the first end and the second end of the test strap to maintainthe first and second ends of the test strap substantially parallel to asurface of the mounting block.

The at least one fastener may define a surface that contacts the teststrap and that extends over the aperture formed in the respective end ofthe test strap.

According to another aspect of the present disclosure, a further testterminal connector for use in selectively interconnecting electricalleads of a railway circuit is provided. The test terminal connectorincludes a mounting block fabricated from a dielectric material; a firstand a second mounting bolt supported in and extending from the mountingblock; and a test strap supported on and extending between the first andsecond mounting bolts, wherein the test strap is constructed of anelectrically conductive material. The test strap includes a first endconnectable to the first mounting bolt; a second end connectable to thesecond mounting bolt; and a goose-neck portion interconnecting the firstend and the second end. The test terminal connector further includes atleast one binding nut selectively connectable to the first and secondmounting bolts, wherein each binding nut is constructed of the samematerial as the test strap and defines planar upper and lower surfaces;and a dielectric spacer disposed between the test strap and anelectrical lead of the railway circuit.

The test strap and each binding nut may be at least coated with at leastone of nickel and a nickel alloy.

Each end of the test strap may define an aperture configured to receivea respective mounting bolt therein.

The dielectric spacer may include an aperture formed therein forreceiving one of the mounting bolts, and a flange extending therefromand being configured for positioning within the aperture of one of thefirst and second ends of the test strap.

A height of the flange of the dielectric spacer may be at least one ofequal to and less than a thickness of the test strap.

The at least one fastener may be supported on the mounting bolt thatsupports the dielectric spacer and may contact the test strap when theat least one fastener is at a lowest most position on the mounting bolt.

The dielectric spacer may include a pair of arms extending therefrom andconfigured to extend at least partially around the test strap. In use,the arms maintain the dielectric spacer supported on the test strap.

The test terminal connector further includes a spacer nut disposed belowone of the first end and the second end of the test strap to maintainthe first and second ends of the test strap substantially parallel to asurface of the mounting block.

The at least one fastener may define a surface that contacts the teststrap and may extend over the aperture formed in the respective end ofthe test strap.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a perspective view of a test terminal connector according toan embodiment of the present disclosure;

FIG. 2 is a side elevational view of the test terminal connector of FIG.1;

FIG. 3 is an exploded perspective view of the test terminal connector ofFIGS. 1 and 2;

FIG. 4 is an exploded, side elevational view of the test terminalconnector of FIGS. 1-3;

FIG. 5 is an enlarged perspective view of a test strap and spacer of thetest terminal connector of FIGS. 1-4;

FIG. 5A is a cross-sectional view of the test strap and spacer of FIG. 5as taken through 5A-5A of FIG. 5; and

FIGS. 6A-6D are top, bottom, right and left side views, respectively, ofthe spacer of the test terminal connector of FIGS. 1-5A.

DETAILED DESCRIPTION OF EMBODIMENTS

Referring to FIGS. 1-6, a test terminal connector, in accordance with anembodiment of the present disclosure, is generally designated as 100. Asseen in FIGS. 1-4, test terminal connector 100 includes a mounting orsupporting block 110 fabricated from a suitable dielectric ornon-conductive material. Mounting block 110 includes structure 112, forexample, in the form of apertures or the like, formed therein forsecuring terminal connector 100 to a suitable substrate or mountingsurface (not shown).

Terminal connector 100 further includes a pair of spaced apart terminalsor mounting bolts 120, 122 mounted or supported in mounting block 110and extending therefrom. Mounting bolts 120, 122 may extend from acommon side of mounting block 110 as shown, or may extend from anysuitable side of mounting block 110. Mounting bolts 120, 122 may befabricated from any suitable conductive material, non-conductivematerial or combination thereof (e.g., a non-conductive core coated orplated with a conductive material or vice-versa). A suitable materialused to coat or plate mounting bolts 120, 122 may include and is notlimited to nickel and nickel alloys. Alternatively, mounting bolts 120,122 may be made entirely of nickel and/or nickel alloys.

Mounting bolts 120, 122 may each be fixedly or releasably secured tomounting block 110. For example, mounting bolts 120, 122 may bethreading received in mounting block 110 in such a manner so as topermit removal of mounting bolts 120, 122 therefrom, or in such a mannerso as to inhibit removal of mounting bolts 120, 122 therefrom. Forexample, lock nuts 124, 126 or the like may be used to secure mountingbolts 120, 122 to mounting block 110.

Suitable washers 130, 132 may be disposed beneath lock nuts 124, 126.Terminal connector 100 further includes at least one other washer 130(two shown) supported on mounting bolt 120, and at least one otherwasher 132 (two shown) supported on mounting bolt 122. Washers 130, 132may be fabricated from any suitable conductive material, non-conductivematerial or combination thereof (e.g., a non-conductive core coated orplated with a conductive material or vice-versa). A suitable materialused to coat or plate washers 130, 132 may include and is not limited tonickel and nickel alloys. Alternatively, washers 130, 132 may be madeentirely of nickel and/or nickel alloys.

Terminal connector 100 further includes a test strap 140 supported onand extending between mounting bolts 120, 122. Test strap 140 includes abody portion 142 defining a first aperture 144 a formed near a first end142 a thereof and a second aperture 144 b formed near a second end 142 bthereof. Test strap 140 includes a goose-neck portion 142 c betweenfirst end 142 a and second end 142 b of body portion 142 therebypositioning first end 142 a of body portion 142 in a plane which isspaced apart from a plane of second end 142 b of body portion 142.

In this manner, when test strap 140 is supported on mounting bolts 120,122, in a first orientation, first end 142 a of body portion 142 islocated relatively further away from mounting block 110 as compared tosecond end 142 b of body portion 142. Alternatively, if test strap 140is supported on mounting bolts 120, 122, in a second orientation, secondend 142 b of body portion 142 is located relatively further away frommounting block 110 as compared to first end 142 a of body portion 142.

Test strap 140 may be fabricated from any suitable conductive material,non-conductive material or combination thereof (e.g., a non-conductivecore coated or plated with a conductive material or vice-versa). Asuitable material used to coat or plate test strap 140 may include andis not limited to nickel and/or nickel alloys. Alternatively, test strap140 may be made entirely of nickel and/or nickel alloys.

A spacer nut or the like 128 may be supported on the mounting bolt 120,122 that supports the end 142 a, 142 b of body portion 142 of test strap140 that is spaced relatively further from the mounting block 110. Forexample, as seen in the figures, spacer nut 128 is provided on mountingbolt 120 and at least partially compensates for the dimensions ofgoose-neck portion 142 c of body portion 142 of test strap 140.

Terminal connector 100 further includes at least one fastening element,in the form of a binding or clamp nut 150 (two shown) operativelyengaged/engageable with or supported on mounting bolt 120, and at leastone binding or clamp nut 152 (two shown) operatively engaged/engageablewith or supported on mounting bolt 122. Binding or clamp nuts 150, 152may be fabricated from any suitable conductive material, non-conductivematerial or combination thereof (e.g., a non-conductive core coated orplated with a conductive material or vice-versa). A suitable materialused to coat or plate binding or clamp nuts 150, 152 may include and isnot limited to nickel and nickel alloys. Alternatively, binding or clampnuts 150, 152 may be made entirely of nickel and/or nickel alloys.

Binding or clamp nuts 150, 152 may include standard RSA-type nuts, AREMA(American Railway Engineering and Maintenance-of-Way Association)14.1.11 nuts or the like. Binding or clamp nuts 150, 152 may includeplanar upper and lower surface which contact the surfaces of bodyportion 142 of test strap 140.

Terminal connector 100 further includes a spacer 160 selectively orfixedly supported on first end 142 a of body portion 142 of test strap140 so as to be interposed between first end 142 a of body portion 142of test strap 140 and spacer nut 138. Spacer 160 is fabricated from anysuitable dielectric, insulative or non-conductive material, includingand not limited to polycarbonate, engineered plastic, Delrin®(polyoxymethylene (POM), acetal resin, polytrioxane andpolyformaldehyde) commercially available from E.I. du Pont de Nemoursand Company, Wilmington Del., and the like. Spacer 160 should bemanufactured from a material which may be used as a metal substitute, islightweight, has low-friction, has good wear-resistance and is capableof operating in temperatures in excess of 90° C. (approx 200° F.).

As seen in FIGS. 3-6D, spacer 160 includes a base portion 162 definingan aperture 162 a formed therein for receiving mounting bolt 120, andmay include a flange, rim or other suitable structure 162 b (see FIGS.3, 4 and 5A) extending from a surface thereof, bounding aperture 162 a,and configured for insertion into first aperture 144 a of first end 142a of test strap 140. In this manner, spacer nut 138 and mounting bolt120 are isolated and/or insulated from test strap 140. As seen in FIG.5A, flange 162 b has a height which is at least one of equal to and lessthan a thickness of first end 142 a of test strap 140. In this manner,binding or clamp nut 150 will contact first end 142 a of test strap 140when binding or clamp nut 150 is fully tightened onto mounting bolt 120.Moreover, in one embodiment, a surface of binding or clamp nut 150, thatcontacts the surface of first end 142 a of test strap 140, may overlieor extend over aperture 144 a formed in first end 142 a of test strap140 and at least partially over flange 162 b of spacer 162.

Spacer 160 may include at least one side wall 164 extending from a sideedge or from a top surface of base portion 162 so as to extend along aside of first end 142 a of test strap 140. As seen in FIGS. 1-6D, a pairof side walls 164 a, 164 b is provided which extend from base portion162 and along opposed sides of first end 142 a of test strap 142. Sidewalls 164 a, 164 b may be located in substantially alignment with flange162 b of spacer 160 when spacer 160 is supported on first end 142 a oftest strap 140.

Spacer 160 may further include at least one arm 166 extending from aside edge or from a top surface of base portion 162 so as to extendalong a side of first end 142 a of test strap 140. As seen in FIGS.1-6D, a pair of arms 166 a, 166 b is provided which extend from baseportion 162 and along opposed sides of first end 142 a of test strap142. Arms 166 a, 166 b define a channel or passage through which firstend 142 a of test strap 140 extends and function to help maintain spacer160 in engagement with or supported on first end 142 a of test strap140. Arms 166 a, 166 b may be located in close proximity to goose-neckportion 142 c of body portion 142 of test strap 140 when spacer 160 issupported on first end 142 a of test strap 140.

In use, terminal connector 100 is electrically connected to a portion ofa railway circuit by means of electrical leads “E1, E2” or the like. Forexample, a first electrical lead “L1” may be connected to mounting bolt120 at a location between lock nut 124 and spacer nut 128, and a secondelectrical lead “L2” may be connected to mounting bolt 122 at a locationbetween lock nut 126 and test strap 140 and/or an arrestor “A”.Electrical lead “L1” may be insulated or separated from lock nut 124 andspacer nut 128 by washers 130. Electrical lead “L2” may be insulated orseparated from test strap 140 by a washer 132.

In operation, over time, as binding or clamp nut 150 is loosened ortightened on mounting bolt 120 to connect/disconnect first electricallead “L1” to terminal connector 100, a surface of binding nut 150 willrepeatedly rub against the surface of first end 142 a of test strap 140.Since the materials of construction of binding nut 150 and test strap140 are the same, the repeated abrasion of binding nut 150 against teststrap 140 will not, over time, result in a high resistance contacttherebetween and thus no intermittence of the railway circuit andpotential unwanted situations.

It is to be understood that while certain forms of this invention havebeen illustrated and described, it is not limited thereto except insofaras such limitations are included in the following claims and allowableequivalents thereof.

1. A spacer, comprising: a base portion defiling a single apertureformed therethrough, the base portion including at least a pair of sideedges, a rear edge, a front edge and a top surface; at least one sidewall extending above the top surface of the base portion from each ofthe pair of side edges of the base portion; and at least one armextending above the top surface of the base portion from each of thepair of side edges of the base portion and from the rear edge of thebase portion.
 2. The spacer according to claim 1, wherein the spacer isa dielectric spacer.
 3. The spacer according to claim 1, wherein eacharm is L-shaped and includes a portion spaced a distance above the topsurface of the base portion and projecting over the top surface of thebase portion.
 4. The spacer according to claim 1, wherein the spacerincludes a first arm at a first corner of the base portion, a second armat a second corner of the base portion, where the first arm and secondarm are aligned with each other, and the at least one side wall includestwo side walls aligned with each other and with the aperture, andwherein the two side walls are spaced an axial distance from the firstarm and the second arm.
 5. The spacer according to claim 1, furthercomprising a flange positioned within the aperture and projecting abovethe top surface of the base portion, wherein the aperture and flange areconfigured to receive a terminal therethrough.
 6. The spacer accordingto claim 1, wherein the spacer is positioned between a test strap and anelectrical lead of a railway circuit.
 7. The spacer according to claim6, wherein a height of a flange positioned within the aperture of thespacer is at least one of equal to and less than a a height of the sidewalls projecting above the top surface of the base portion.
 8. Thespacer according to claim 6, wherein the at least one arm is configuredto partially extend around the test strap.
 9. The spacer according toclaim 6, wherein the at least one arm facilitates maintaining continuouscontact between the spacer and the test strap.
 10. The spacer accordingto claim 6, wherein the spacer supports a portion of the test strap sothat the spacer is interposed between the portion of the test strap andat least one fastening element.
 11. A terminal connector, comprising: afirst terminal and a second terminal; a test strap extending between andconfigured to receive the first terminal and the second terminal; and aspacer, including: a base portion defining a single aperture formedtherethrough and wherein one of the first terminal and the secondterminal extends through the single aperture, the base portion includingat least a pair of side edges, a rear edge, a front edge and a topsurface; at least one side wall extending above the top surface of thebase portion from each of the pair of side edges of the base portion;and at least one arm extending above the top surface of the base portionfrom each of the pair of side edges of the base portion and from therear edge of the base portion, wherein the test strap extends from therear edge of the base portion of the spacer such that the side walls andthe arms of the spacer are disposed along opposed edges of the teststrap.
 12. The terminal connector according to claim 11, wherein theterminal connector interconnects electrical leads of a railway circuit.13. The terminal connector according to claim 11, wherein the test strapis constructed of at least one electrically conductive material.
 14. Theterminal connector according to claim 11, wherein the test strap iscoated with at least one of nickel and nickel alloy.
 15. The terminalconnector according to claim 11, wherein the test strap includes agoose-neck portion interposed between a first end and a second endthereof, wherein the goose-next portion abuts the rear edge of thespacer, and wherein the first end and the second end of the test strapeach define an aperture formed therein.
 16. The terminal connectoraccording to claim 11, wherein the first terminal is a first mountingbolt and the second terminal is a second mounting bolt.
 17. The terminalconnector according to claim 11, wherein the plurality of componentsinclude at least one fastening element for connecting the first terminaland the second terminal to the test strap, and wherein the spacer isinterposed between the at least one fastening element and the teststrap.
 18. The terminal connector according to claim 17, wherein the atleast one fastening element is constructed from a same material as thetest strap.
 19. The terminal connector according to claim 17, whereinthe at least one fastening element includes at least one nut configuredfor threaded engagement with a respective mounting bolt.
 20. Theterminal connector according to claim 17, wherein the at least onefastening element defines a surface that contacts the test strap andextends over an aperture formed in the respective ends of the teststrap.
 21. The terminal connector according to claim 17, furthercomprising a mounting block for mounting the at least one fasteningelement and being configured to support the first terminal, the secondterminal, and the test strap.
 22. The terminal connector according toclaim 21, wherein the spacer is configured to continuously maintain afirst end and a second end of the test strap in parallel with a surfaceof the mounting block.